Switchable electrical composite pane array

ABSTRACT

A composite switchable pane array, having: a first pane; a second pane, and an intermediate layer arranged therebetween, wherein the intermediate layer has at least one first thermoplastic polymer film and one second thermoplastic polymer film, and an SPD film arranged therebetween; and an edge sealing arranged in the outer edge region of the intermediate layer, containing a polyimide (PI) and/or polyisobutylene (FIB).

CROSS REFERENCE TO RELATED APPLICATIONS

The present application is a continuation of U.S. patent application Ser. No. 14/417,788 filed Jan. 27, 2015, which, in turn, is the US national stage of International Patent Application PCT/EP2013/063628 filed internationally on Jun. 28, 2013, which, in turn, claims priority to European Patent Application No. 12179771.6 filed on Aug. 9, 2012. All of which are incorporated by reference in their entirety, including any drawings.

The invention relates to an electrically switchable composite pane arrangement, methods for production thereof, and its use as motor vehicle and architectural glazing.

Glazings that alter their light transmittance at the push of a button and can thus change between a dark and transparent appearance are widespread in the art. In particular, many possibilities present themselves in the motor vehicle industry. At the height of summer and with strong sunlight, the passenger compartment can be very greatly heated through the window openings. In addition, the driver can be blinded by scattered light while driving. In particular, with roof glazings of motor vehicles, the motor vehicle can be heated up rapidly and strongly in the summer. This heating of the motor vehicle interior has a negative impact not only on the driver's ability to concentrate and to react but also increases the energy and fuel consumption of the motor vehicle to a not insubstantial extent.

Various possibilities exist for regulation of the light transmittance of a pane, for example, in electrochromic glazings or liquid crystal displays (LCDs).

U.S. Pat. No. 6,277,523 B1 describes the construction and operation of an electrochromic coating. The transparency to light of different wavelengths can be controlled and regulated by the application of an electrical load.

JP 2008-025229 A1 discloses a system for altering the light transmittance in double façades. This enables regulation of the amount of incident light and, consequently, the amount of heat in the building. The transmittance control is controlled by nucleation processes, i.e., formation of droplets of a gas in the intermediate layer.

US 2004257649 A1 discloses a multipart architectural glazing with an electrically switchable SPD film.

US 2005/0227061 A1 discloses a method for producing and laminating an SPD film (suspended particle device). The actual SPD film is laminated between adhesive films under the action of heat and vacuum.

EP 2 010 385 B1 discloses a composite glazing with a multilayer intermediate layer. The intermediate layer contains at least three adhesive films, a layer with an infrared reflective function, and an electrical device. This includes a device with a liquid crystal layer or an SPD film. The electrical device is arranged inside a cut-out in an adhesive film.

EP 2 013 013 B1 discloses a composite glazing with an at least three-ply intermediate layer. A middle intermediate layer forms the framework for an SPD film and is laminated together with a bottom intermediate layer and top intermediate layer. As a significant condition, the intermediate layer materials contain no plasticizer.

A frequent problem with laminated glazings is the premature aging of the intermediate films. Especially in conjunction with the UV-radiation of sunlight, penetrating moisture and oxygen can result in an at least superficial degradation of the adhesive film. Consequently, the quality of the edge sealing has a great influence on the quality and long-term stability of the entire glazing. If there are, additionally, inorganic functional layers, in particular metallic functional layers, the aging of the intermediate layers increases significantly more.

Aging can not only affect the overall visual appearance of the glazing, but can also significantly reduce the functionality. In particular, in the region of the outer edges of the glazing, the functionality of the glazing can be significantly reduced. In the area of glazings with SPD films, this means that the color change is delayed in the edge region or can even be completely absent. In particular, when voltage is not applied, the glazing appears increasingly brighter in the edge region. This brightening effect can, over time, spread over the entire area of the glazing.

The object of the invention consists in providing an electrically switchable glazing with SPD film that has high and long-lasting aging stability of the functional layer.

The object of the present invention is accomplished according to the disclosure. Preferred embodiments also emerge from the disclosure.

Two methods according to the invention for producing an electrically switchable glazing with SPD film and its use emerge from further from the disclosure.

The switchable composite pane arrangement according to the invention comprises at least one first pane, a second pane, and an intermediate layer arranged therebetween. The pane preferably contains flat glass, float glass, quartz glass, borosilicate glass, soda lime glass, and/or mixtures thereof. Alternatively, the pane can also include polymers such as polycarbonate or polymethyl methacrylate (PLEXIGLAS® [acrylic glass]). The intermediate layer contains at least one first thermoplastic polymer film and one second thermoplastic polymer film as well as an electrically switchable transmittance-variable SPD film arranged therebetween. SPD (suspended particle device) films and foils contain colloidal particles in the preferred size range of less than 1 μm. The particles are suspended in a solution or, preferably, in a polymer matrix. In the absence of an electrical field, the colloidal particles are arranged and oriented randomly in the medium. In this state, incident light is absorbed or reflected; the SPD film appears dark and opaque. Upon application of an electrical field, the colloidal particles become aligned. An incident light beam can pass and the SPD film appears transparent. Through variation of the voltage, even a gradual change in the light transmittance of the SPD film is possible. A detailed description SPD films is found, for example, in US 2005/0227061 A1, in particular in [0004] to [0015], a method for the lamination of a pane with SPD film in [0016]. The thermoplastic polymer film preferably contains PVB (polyvinyl butyral) or EVA (polyethyl vinyl acetate). Optionally, polybutylene terephthalate (PBT), polycarbonate (PC), polyethylene terephthalate (PET), and polyethylene naphthalate (PEN), polyvinyl chloride (PVC), polyvinyl fluoride (PVF), polyvinyl butyral (PVB) without plasticizers, and/or copolymers thereof, particularly preferably polyethylene terephthalate (PET) can also be contained. An edge sealing is arranged in the outer edge region, preferably the entire outer edge region of the electrically switchable transmittance-variable SPD film. The edge sealing, preferably as an insulation film, contains a polyimide (PI) and/or polyisobutylene (PIB).

In the context of the invention, the term SPD film means a multilayer film in which the actual active SPD film is arranged congruently between at least one first and at least one second carrier film. The advantage of SPD films resides in simple production of the switchable composite pane arrangement. The SPD film can be prepared in relatively large quantities before production of the pane arrangement and, during production, can be simply inserted into the composite, which is then laminated by conventional methods to form the composite pane.

The carrier films preferably contain at least one thermoplastic polymer, particularly preferably polyethylene terephthalate (PET). The thickness of each carrier film is preferably from 0.1 mm to 1 mm, particularly preferably from 0.1 mm to 0.2 mm.

The edge sealing preferably extends from the outer edge region of the electrically switchable transmittance-variable SPD film at least 1 mm in the direction of the interior surface of the SPD film. The edge sealing preferably comprises a polyimide foil or film. In the context of the invention, the term “outer edge region” means the cut edges of the horizontal flat film. Covering using the edge sealing reduces the aging of the intermediate layer significantly and measurably. The polyimide-containing composition of the edge sealing surprisingly demonstrates better aging protection than, for example, a commercially available adhesive tape (“TESAFILM®” [cellophane tape]).

In an alternative embodiment, the edge sealing is implemented as an at least 1-mm-deep notch in the region of the intermediate layer. The notch extends at least to the SPD film and is filled polyisobutylene (PIB) and/or polyurethane (PU). This edge sealing effectively protects the SPD film against aging and extends the service life of the switchable pane arrangement.

The thermoplastic polymer films preferably contain PVB (polyvinyl butyral) and/or EVA (polyethyl vinyl acetate). A polymer film made of EVA surprisingly presents, in conjunction with the edge sealing according to the invention, which contains polyimides (PI) and/or polyisobutylenes, the highest protection against aging. This is likely attributable to a very strong bonding of the edge sealing according to the invention and the EVA (polyethyl vinyl acetate) during the lamination of the glazing.

The switchable composite pane arrangement preferably includes a third thermoplastic polymer film between the first pane and the second thermoplastic polymer film. This third thermoplastic polymer film can contribute to the improvement of the mechanical properties, for example, breakage resistance. Alternatively, the third thermoplastic film can also serve as a carrier for other functions, for example, protection against the sun.

The switchable composite pane arrangement preferably includes an IR (infrared)-radiation reflective coating between the third thermoplastic polymer film and the second thermoplastic polymer film.

The IR-radiation-reflective coating preferably contains niobium, tantalum, molybdenum, zirconium, silver, gold, aluminum, nickel, chromium, copper, and/or mixtures or alloys thereof.

The electrically switchable transmittance-variable SPD film preferably has an edge set back (cut-out) by 1 mm to 4 mm more than the first thermoplastic polymer film and the second thermoplastic polymer film. This has the effect that the first thermoplastic film and the second thermoplastic film surrounding the SPD film extend beyond the outer edge of the SPD film by 1 mm to 4 mm. In conjunction with the edge sealing according to the invention, this protrusion of the thermoplastic films again significantly increases the aging resistance of the SPD films and of the entire switchable composite pane arrangement.

The edge sealing preferably includes a sheath made of polyurethane, which further increases the aging resistance.

The electrically switchable transmittance-variable SPD film preferably has a thickness from 100 μm to 500 μm, preferably 150 μm to 400 μm.

The electrically switchable transmittance-variable SPD film preferably includes an electrical contact. The electrical contact is connected to a voltage source and a control element which thus enables a change, preferably even a gradual change, of the transmittance of switchable composite pane arrangement.

The edge sealing preferably has a polyacrylic adhesive. In a preferred embodiment, the edge sealing is implemented as an insulating film; the polyacrylic adhesive fixes the insulating film on the electrically switchable SPD film.

The invention further includes a method for producing a switchable composite pane arrangement. In a first step, an electrically switchable transmittance-variable SPD film is sheathed in its outer edge region with an edge sealing (4) containing a polyimide (PI). The edge sealing is preferably implemented as an insulating film including a polyimide film with a polyacrylic adhesive. The sheathed electrically switchable transmittance-variable SPD film forms a film.

In the next step, the film is arranged between a first thermoplastic polymer film and a second thermoplastic polymer film to form an intermediate layer. The first thermoplastic polymer film and the second thermoplastic polymer film are arranged such that the thermoplastic polymer films have an outer edge protrusion at least 2 mm greater than the electrically switchable transmittance-variable SPD film. Preferably, the electrically switchable transmittance-variable SPD film is also provided with an electrical contact.

In the next step, the intermediate layer is laminated between a first pane and a second pane. In further steps, the resultant composite glazing can also be provided with an electrical control device.

The invention further includes an alternative method for producing a switchable composite pane arrangement. An electrically switchable transmittance-variable SPD film is arranged to form an intermediate layer between a first thermoplastic polymer film and a second thermoplastic polymer film.

The intermediate layer is subsequently laminated between a first pane and a second pane.

In a next step, a 1-mm-to-5-mm-deep notch is milled in the region of the electrically switchable transmittance-variable SPD film. In the following steps, the notch is filled with polyisobutylene (PIB) and then with polyurethane (PU).

The invention further includes the use of the switchable composite pane arrangement according to the invention as a motor vehicle glazing, ship glazing, train glazing, aircraft glazing, and/or architectural glazing.

The invention is explained in detail in the following with reference to drawings. The drawings are a purely schematic representation and are not true to scale. They in no way restrict the invention.

They depict:

FIG. 1 a cross-section of an electrically switchable composite pane arrangement according to the prior art,

FIG. 2 a cross-section of an electrically switchable composite pane arrangement according to the invention,

FIG. 3 a cross-section of a preferred electrically switchable composite pane arrangement according to the invention,

FIG. 4 a cross-section of another preferred electrically switchable composite pane arrangement according to the invention,

FIG. 5 a flowchart for producing the electrically switchable composite pane arrangement according to the invention, and

FIG. 6 a flowchart for alternative producing of the electrically switchable composite pane arrangement according to the invention.

FIG. 1 depicts a cross-section of an electrically switchable composite pane arrangement according to the prior art. A thermoplastic intermediate layer (3) is arranged between a first pane (1) and a second pane (2). The thermoplastic intermediate layer (3) comprises one first thermoplastic polymer film (3 a) and one second thermoplastic polymer film (3 c) as well as an electrically switchable transmittance-variable SPD film (3 b) arranged therebetween. A voltage source is connected to the electrically switchable transmittance-variable SPD film (3 b) by an electrical contact (not shown).

FIG. 2 depicts a cross-section of an electrically switchable composite pane arrangement according to the invention. A thermoplastic intermediate layer (3) is arranged between a first pane (1) and a second pane (2). The thermoplastic intermediate layer (3) comprises one first thermoplastic polymer film (3 a) and one second thermoplastic polymer film (3 c) as well as an electrically switchable transmittance-variable SPD film (3 b) arranged therebetween. An edge sealing (4) is arranged in the outer edge region (5) of the electrically switchable transmittance-variable SPD film (3 b). The edge sealing contains a polyimide (PI) with the edge sealing (4) extending from the outer edge region (5) with the length (L) of at least 1 mm above (I) and below (II) the SPD film (3 b) between the first thermoplastic polymer film (3 a) and the second thermoplastic polymer film (3 c). The edge sealing (4) is preferably implemented as a polyimide film.

FIG. 3 depicts a cross-section of a preferred electrically switchable composite pane arrangement according to the invention. The basic structure corresponds to that depicted in FIG. 2. In addition, a third thermoplastic polymer film (3 d) is arranged between the first pane (1) and the intermediate layer (3). Moreover, an IR-radiation-reflective coating (6), for example, silver, is arranged between the third thermoplastic polymer film (3 d) and the intermediate layer (3).

FIG. 4 depicts a cross-section of an alternative preferred electrically switchable composite pane arrangement according to the invention. The basic structure corresponds, except for the edge sealing (4), to that depicted in FIG. 2. A notch (7) that is filled with an edge sealing (4) made of polyisobuthylene and polyurethane is situated in the edge region of the intermediate layer (3).

FIG. 5 depicts a flowchart for producing the electrically switchable composite pane arrangement according to the invention. In a first step, an electrically switchable transmittance-variable SPD film (3 b) is sheathed in its outer edge region with an edge sealing (4) containing a polyimide (PI). The edge sealing (4) is preferably implemented as an insulating film comprising a polyimide film with a polyacrylic adhesive. The sheathed electrically switchable transmittance-variable SPD film (3 b) forms a film. In the next step, the film is arranged between a first thermoplastic polymer film and a second thermoplastic polymer film such that the thermoplastic polymer films (3 a, 3 c) have an edge protrusion at least 2 mm greater than the film. In final steps (not depicted), the electrically switchable transmittance-variable SPD film (3 b) is also provided with an electrical contact and an electrical controller.

FIG. 6 depicts a flowchart for alternative production of the electrically switchable composite pane arrangement according to the invention. An electrically switchable transmittance-variable SPD film (3 b) is arranged to form an intermediate layer (3) between a first thermoplastic polymer film (3 a) and a second thermoplastic polymer film (3 c). The resultant intermediate layer (3) is subsequently laminated between a first pane (1) and a second pane (2). In a next step, a notch (7) is milled at least 1 mm into the intermediate layer (3) in the region of the electrically switchable transmittance-variable SPD film (3 b). In the following steps, the notch (7) is filled with polyisobutylene (PIB). After curing of the polyisobutylene, the notch (7) is then sealed with polyurethane (PU).

In the following, the invention is explained in detail with reference to two examples and one comparative example. The examples in no way limit the invention.

1. Example (According to the Invention)

A glass composite pane (20 cm×20 cm) contained the following structure (thickness indicated) made of a first pane (1) (2.1 mm), a first thermoplastic polymer film (3 a) (EVA, 0.38 mm), an SPD film (3 b)(0.35 mm), a second thermoplastic polymer film (3 c) (EVA, 0.38 mm), PET with silver coating (6)(0.05 mm), a third thermoplastic polymer film (3 c) (EVA, 0.38 mm), a second pane (2) (2.1 mm). The SPD film (3 b) was sheathed in the edge region as depicted in FIGS. 2 and 3 with an edge sealing (4) made of polyimide film. The thermoplastic films (3 a, 3 c) made of EVA had, compared to the SPD film (3 b), a protrusion of roughly 2 mm. The glass composite pane was subjected to heated storage for 28 days at 90° C. and a WOM (Weather-Ometer test) for 1000 hours at 90° C. and irradiation by a xenon lamp (PV3929) with energy of 1250 W/h*m².

2. Example (According to the Invention)

A glass composite pane (20 cm×20 cm) contain the following structure (thickness indicated) made of a first pane (1)(2.1 mm), a first thermoplastic polymer film (3 a) (EVA, 0.38 mm), an SPD film (3 b) (0.35 mm), a second thermoplastic polymer film (3 c) (EVA, 0.38 mm), PET with silver coating (6) (0.05 mm), a third thermoplastic polymer film (3 c) (EVA, 0.38 mm), a second pane (2) (2.1 mm). The SPD film (3 b) was sheathed in the edge region as depicted in FIG. 4 with an edge sealing (4) made of polyisobutylene and polyurethane. The glass composite pane was subjected, as in Example 1, to heated storage for 28 days at 90° C. and a WOM (Weather-Ometer test) for 1000 hours at 90° C. and irradiation by a xenon lamp (PV3929) with energy of 1250 W/h*m².

3. Comparative Example (Prior Art)

The glass composite pane corresponded to that in Example 1 and 2 without sealing of the SPD film (3 b). The glass composite pane was subjected as in Example 1 and 2 to heated storage for 28 days at 90° C. and a WOM test (Weather® meter test) for 1000 hours at 90° C. and irradiation by xenon lamp (PV3929) with energy of 1250 W/h*m².

The results of the tests of the examples are presented in Table 1. In the examples, the degeneration of the SPD film in the edge region was measured after the test runs “heated storage” and “WOM test”. The degeneration of the SPD film is evidenced by brightening of the SPD film in the de-energized state. Table 1 indicates in mm the size of the edge region of the SPD film that appears bright in the de-energized state. This region is thus no longer (fully) functional.

TABLE 1 Degradation of the SPD film in the outer edge region Heated storage WOM Test Example 1 <0.5 mm <1 mm Example 2 <1 mm <2 mm Comparative Example 3 >5 mm >5 mm

Example 1 and Example 2 according to the invention present, both with heated storage and also with the WOM Test, only very minimal and negligible damage to the edge of the SPD film. Thus, the declines in the functioning edge region move, depending on the test conditions, between 0.5 mm and 2 mm. In the Comparative Example 3, the damage to the edge (>5 mm) of the SPD film is higher by a factor of 2.5 to 10 than in the Example according to the invention. These results were surprising and not obvious to the person skilled in the art. Insulation of the SPD film with commercially available TESAFILM® [cellophane tape] yields values similar to Comparative Example 3.

LIST OF REFERENCE CHARACTERS

-   (1) first pane -   (2) second pane -   (3) intermediate layer -   (3 a) first thermoplastic polymer film -   (3 b) electrically switchable transmittance-variable SPD film -   (3 c) a second thermoplastic polymer film -   (3 d) third thermoplastic polymer film -   (4) edge sealing -   (5) outer edge region -   (6) IR-radiation-reflective coating -   (7) notch -   (L) length of the edge sealing along the SPD film -   (I) surface above the SPD film -   (II) surface below the SPD film 

1. A switchable composite pane arrangement, comprising: a first pane; a second pane; an intermediate layer arranged therebetween, wherein the intermediate layer contains at least one first thermoplastic polymer film and one second thermoplastic polymer film as well as one suspended particle device (SPD) film arranged therebetween; and an edge sealing arranged in an outer edge region of the intermediate layer, containing a polyimide (PI), wherein the edge sealing covers the SPD film in a region of an outer edge of the SPD film and runs with a length (L) of at least 1 mm above and below the inner surfaces of the SPD film, wherein the edge sealing comprises a polyimide film, wherein an outer edge of the first thermoplastic polymer film and an outer edge of the second thermoplastic polymer film exceed the covered outer edge of the SPD film by at least 2 mm, and wherein the outer edge of the first thermoplastic film and the outer edge of the second thermoplastic film merge during a lamination process so to surround the SPD film.
 2. The switchable composite pane arrangement according to claim 1, wherein a third thermoplastic polymer film is arranged between the first pane and the second thermoplastic polymer film.
 3. The switchable composite pane arrangement according to claim 2, wherein an IR-radiation-reflective coating is arranged between the third thermoplastic polymer film and the second thermoplastic polymer film.
 4. The switchable composite pane arrangement according to claim 3, wherein the IR-radiation-reflective coating contains niobium, tantalum, molybdenum, zirconium, silver, gold, aluminum, nickel, chromium, copper, and/or mixtures or alloys thereof.
 5. The switchable composite pane arrangement according to claim 1, wherein the thermoplastic polymer films contain PVB (polyvinyl butyral) and/or EVA (polyethyl vinyl acetate).
 6. The switchable composite pane arrangement according to claim 1, wherein the thermoplastic polymer films contain polyethyl vinyl acetate.
 7. The switchable composite pane arrangement according to claim 1, wherein the SPD film has an external edge set back by 1 mm to 4 mm relative to the first thermoplastic polymer film and the second thermoplastic polymer film.
 8. The switchable composite pane arrangement according to claim 1, wherein the SPD film has a thickness from 100 μm to 500 μm.
 9. The switchable composite pane arrangement according to claim 1, wherein the SPD film has a thickness from 150 μm to 400 μm.
 10. The switchable composite pane arrangement according to claim 1, wherein the SPD film comprises an electrical contact.
 11. The switchable composite pane arrangement according to claim 1, wherein the edge sealing includes a polyacrylic adhesive.
 12. A method for producing a switchable composite pane arrangement, comprising: sheathing a suspended particle device (SPD) film in its outer edge region by an edge sealing, containing a polyimide (PI), thus obtaining a film, wherein the edge sealing is configured as isolating film comprising a polyimide film and a polyacylate glue; arranging the sheathed SPD film between a first thermoplastic polymer film and a second thermoplastic polymer film to form an intermediate layer, wherein an outer edge of the first thermoplastic polymer film and an outer edge of the second thermoplastic polymer film exceed an outer edge of the sheathed SPD film by at least 2 mm; and laminating the intermediate layer and the sheathed SPD film between a first pane and a second pane, wherein the laminating causes the outer edge of the first thermoplastic film and the outer edge of the second thermoplastic film to merge so to surround the SPD film.
 13. A method, comprising: providing a switchable composite pane arrangement; and using the arrangement as motor vehicle glazing, ship glazing, train glazing, aircraft glazing, and/or architectural glazing, wherein the switchable composite pane arrangement includes a first pane, a second pane, and an intermediate layer arranged therebetween, wherein the intermediate layer contains at least one first thermoplastic polymer film and one second thermoplastic polymer film as well as one suspended particle device (SPD) film arranged therebetween, and an edge sealing arranged in the outer edge region of the intermediate layer, containing a polyimide (PI) and/or polyisobutylene (FIB), wherein the edge sealing covers the SPD film in the outer edge region and runs with a length (L) of at least 1 mm above and below the inner surfaces of the SPD film, wherein the edge sealing comprises a polyimide film, wherein an outer edge of the first thermoplastic polymer film and an outer edge of the second thermoplastic polymer film exceed by at least 2 mm the covered outer edge of the SPD film, and wherein the outer edge of the first thermoplastic film and the outer edge of the second thermoplastic film merge during a lamination process so to surround the SPD film. 